Electronic Position Switches | Application manual | ABB Robotics

ABB Robotics

Application manualElectronic Position Switches

Trace back information:Workspace R12-2 version a11 (not checked in)Published 2012-10-25 at 08:34:22Skribenta version 1184

Application manualElectronic Position Switches

RobotWare 5.15.01

Document ID: 3HAC027709-001Revision: J ongoing

© Copyright 2006-2012 ABB. All rights reserved.

The information in this manual is subject to change without notice and should notbe construed as a commitment by ABB. ABB assumes no responsibility for any errorsthat may appear in this manual.Except as may be expressly stated anywhere in this manual, nothing herein shall beconstrued as any kind of guarantee or warranty by ABB for losses, damages topersons or property, fitness for a specific purpose or the like.In no event shall ABB be liable for incidental or consequential damages arising fromuse of this manual and products described herein.This manual and parts thereof must not be reproduced or copied without ABB'swritten permission.Additional copies of this manual may be obtained from ABB.The original language for this publication is English. Any other languages that aresupplied have been translated from English.

© Copyright 2006-2012 ABB. All rights reserved.ABB AB

Robotics ProductsSE-721 68 Västerås

Sweden

Table of contents7Overview of this manual ...................................................................................................................9Product documentation, M2004 .......................................................................................................

11Safety ................................................................................................................................................

131 Introduction131.1 Overview of Electronic Position Switches ..............................................................161.2 Terminology .....................................................................................................

172 Electronic Position Switches functions172.1 Monitor Axis Range ...........................................................................................202.2 Cyclic Sync Check .............................................................................................212.3 Software Sync Check .........................................................................................222.4 Control Error Supervision ...................................................................................232.5 Operational Safety Range ...................................................................................

253 Installation253.1 Hardware installation .........................................................................................253.1.1 I/O connector data ...................................................................................283.1.2 I/O signals .............................................................................................323.1.3 Power supply .........................................................................................343.1.4 SMB connection for additional axis .............................................................353.2 Software installation ..........................................................................................353.2.1 Installing required software .......................................................................

374 Configuration374.1 Create a safety user ...........................................................................................394.2 EPS Configuration Wizard ...................................................................................514.3 Configuration for robots with non-zero calibration position ........................................544.4 Configuration for MultiMove ................................................................................564.5 Activating the safety configuration ........................................................................584.6 Validate the configuration ...................................................................................604.7 Viewing the configuration on the FlexPendant ........................................................

615 Synchronization615.1 Synchronization guidelines for Cyclic Sync Check ...................................................635.2 Synchronization guidelines for Software Sync Check ...............................................

656 Running in production656.1 Reaction time ...................................................................................................666.2 Recovery after safety violation .............................................................................676.3 Virtual signals ...................................................................................................686.4 Status LED .......................................................................................................

697 Example application697.1 Example with two work zones ..............................................................................

738 Safety aspects for Electronic Position Switches738.1 Overview .........................................................................................................748.2 Safety requirements ..........................................................................................748.2.1 Standards conformance ...........................................................................758.2.2 Specific safety requirements .....................................................................768.3 Safe design of Electronic Position Switches ...........................................................798.4 Certifications ....................................................................................................808.5 Conclusion .......................................................................................................

3HAC027709-001 Revision: J ongoing 5© Copyright 2006-2012 ABB. All rights reserved.

Table of contents

81Index

6 3HAC027709-001 Revision: J ongoing© Copyright 2006-2012 ABB. All rights reserved.

Table of contents

Overview of this manualAbout this manual

This manual describes the Electronic Position Switches option and containsinstallation descriptions of the hardware. It also describes the add-in software,which is added to RobotStudio and used for configuration of Electronic PositionSwitches.

UsageThis manual should be used during installation and configuration of ElectronicPosition Switches.

Who should read this manual?This manual is mainly intended for:

• personnel that are responsible for installations and configurations ofhardware/software

• personnel that make configurations of the I/O system• system integrators

PrerequisitesThe reader should have the required knowledge of:

• mechanical installation work• electrical installation work• working with industrial robots• using RobotStudio• personal safety, see the safety chapter in Product manual - IRC5.

Organization of chaptersThe manual is organized in the following chapters:

ContentsChapter

This chapter gives an overview of the Electronic PositionSwitches option, and describes the purpose.

1Introduction

Descriptions of all functions included in Electronic PositionSwitches.

2Electronic PositionSwitches functions

Workflows for how to install hardware and software for ElectronicPosition Switches.

3Installation

Workflows for how to configure Electronic Position Switches.4Configuration

Describes some considerations for the required synchronization.5Synchronization

Information that is useful after installation, such as performancespecifications, what to do if the supervision triggers and virtualsignals that can be used in a RAPID program.

6Running in production

Example of a typical problem that is solved with Electronic Po-sition Switches.

7Example application

Describes how Electronic Position Switches complies with rel-evant safety standards and regulations.

8Safety aspects for Elec-tronic Position Switches

Continues on next page3HAC027709-001 Revision: J ongoing 7


Overview of this manual

References

Document IDReference

3HAC032104-001Operating manual - RobotStudio

3HAC021313-001Product manual - IRC5

3HAC16581-1Technical reference manual - RAPID Instructions, Functionsand Data types

3HAC027097-001Operating manual - Getting started, IRC5 and RobotStudio

Revisions

DescriptionRevision

First edition. Released with Electronic Position Switches.-

Installation procedure removed from this manual. Installation and replacementinformation can be found in Product manual - IRC5.

A

Information added about test pulses on output signals.Example application added.Minor corrections.

Added section about reaction time.BIn the EPS Configuration Wizard, the configuration of Monitor Axis Range hasa new checkbox called Invert function, which is described.

New chapter added, Safety aspects for Electronic Position Switches. Addi-tions/corrections are made.

C

Added section Configuration for robots with non-zero calibration position onpage 51.

D

Added information to Create RAPID program for synchronization on page 61.Corrections following updates in the user interface in EPSConfigurationWizardon page 39.Added section Status LED on page 68.Correction in section Virtual signals on page 67. The virtual signals cannot beused in a RAPID program.Added information to section Installing required software on page35, that EPSConfiguration Wizard is pre-installed in RobotStudio from RobotWare 5.11.

Updated section Installing required software on page35: the EPS ConfigurationWizard is installed with RobotStudio.

E

Software Sync Check is introduced as alternative to Cyclic Sync Check.Added section Viewing the configuration on the FlexPendant on page 60.Updated safety signal graphics for the levels Danger and Warning.

The grant Execute program is added in sectionCreate a safety user on page37.F

Added section Supported additional axes on page 14.GNew grant described in sectionGranting right to perform software synchroniz-ation on page 38.

Updated section Power supply on page32with information regarding commonground potential.

H

Updated sectionSMB connection for additional axis on page34with informationregarding the SMB connection.

J ongoing


Overview of this manual

Continued

Product documentation, M2004Categories for manipulator documentation

The manipulator documentation is divided into a number of categories. This listingis based on the type of information in the documents, regardless of whether theproducts are standard or optional.All documents listed can be ordered from ABB on a DVD. The documents listedare valid for M2004 manipulator systems.

Product manualsManipulators, controllers, DressPack/SpotPack, and most other hardware will bedelivered with a Product manual that generally contains:

• Safety information.• Installation and commissioning (descriptions of mechanical installation or

electrical connections).• Maintenance (descriptions of all required preventive maintenance procedures

including intervals and expected life time of parts).• Repair (descriptions of all recommended repair procedures including spare

parts).• Calibration.• Decommissioning.• Reference information (safety standards, unit conversions, screw joints, lists

of tools ).• Spare parts list with exploded views (or references to separate spare parts

lists).• Circuit diagrams (or references to circuit diagrams).

Technical reference manualsThe technical reference manuals describe reference information for roboticsproducts.

• Technical reference manual - Lubrication in gearboxes: Description of typesand volumes of lubrication for the manipulator gearboxes.

• Technical reference manual - RAPID overview: An overview of the RAPIDprogramming language.

• Technical referencemanual - RAPID Instructions, Functions and Data types:Description and syntax for all RAPID instructions, functions, and data types.

• Technical reference manual - RAPID kernel: A formal description of theRAPID programming language.

• Technical reference manual - System parameters: Description of systemparameters and configuration workflows.

Application manualsSpecific applications (for example software or hardware options) are described inApplication manuals. An application manual can describe one or severalapplications.



Product documentation, M2004

An application manual generally contains information about:• The purpose of the application (what it does and when it is useful).• What is included (for example cables, I/O boards, RAPID instructions, system

parameters, DVD with PC software).• How to install included or required hardware.• How to use the application.• Examples of how to use the application.

Operating manualsThe operating manuals describe hands-on handling of the products. The manualsare aimed at those having first-hand operational contact with the product, that isproduction cell operators, programmers, and trouble shooters.The group of manuals includes (among others):

• Operating manual - Emergency safety information• Operating manual - General safety information• Operating manual - Getting started, IRC5 and RobotStudio• Operating manual - Introduction to RAPID• Operating manual - IRC5 with FlexPendant• Operating manual - RobotStudio• Operatingmanual - Trouble shooting IRC5, for the controller and manipulator.


Product documentation, M2004

Continued

SafetySafety of personnel

When working inside the robot controller it is necessary to be aware ofvoltage-related risks.A danger of high voltage is associated with the following parts:

• Units inside the controller, for example I/O units, can be supplied with powerfrom an external source.

• The mains supply/mains switch.• The power unit.• The power supply unit for the computer system (230 VAC).• The rectifier unit (400-480 VAC and 700 VDC). Capacitors!• The drive unit (700 VDC).• The service outlets (115/230 VAC).• The power supply unit for tools, or special power supply units for the

machining process.• The external voltage connected to the controller remains live even when the

robot is disconnected from the mains.• Additional connections.

Therefore, it is important that all safety regulations are followed when doingmechanical and electrical installation work.

Safety regulationsBefore beginning mechanical and/or electrical installations, ensure you are familiarwith the safety regulations described in Product manual - IRC5.


Safety

This page is intentionally left blank

1 Introduction1.1 Overview of Electronic Position Switches

PurposeElectronic Position Switches is a safety controller in the robot system. The purposeof the safety controller is to ensure a high safety level in the robot system usingelectronic position switches and safe digital output signals.The output signals can be connected to, for instance, a safety PLC that will generatestops in the robot system by opening the safety chain. The safety controller alsosends status signals to the main computer, that is the standard IRC5 robotcontroller.Some examples of applications:

• Monitoring of all robot axes.• Replacing mechanical position switches.

WARNING

The safety controller has passive monitoring, i.e. it does not stop the robot. If anaxis is outside its configured range, an output signal goes low. It is theresponsibility of the installation personnel to connect the output signals in sucha way that the robot is stopped if there is a risk of a dangerous situation.

What is includedThe following is included with the option Electronic Position Switches [810-1]:

• Safety controller (3HAC026271-001)• 14 pole plug contact for I/O connections.

The option Electronic Position Switches gives you access to EPS ConfigurationWizard functionality in RobotStudio.With EPS Configuration Wizard you can:

• set up monitoring of all robot axes• quickly modify the monitoring settings.

Basic approachThis is the general approach for setting up Electronic Position Switches. For moredetailed instructions of how this is done, see chapters Installation andConfiguration.

1 Connect I/O connections to sync switch and safety PLC, or similar.2 Create a safety user in the User Authorization System, UAS (using

RobotStudio).3 Configure the settings for Electronic Position Switches functions via the EPS

Configuration Wizard and restart the controller.4 Log on as safety user and set the PIN code on the FlexPendant. Restart the

controller.




5 Synchronize the safety controller, using a sync switch or softwaresynchronization.Now the monitoring functions are activated.

6 Validate the configuration.

LimitationsElectronic Position Switches can only monitor one additional axis. This axis mustbe connected to SMB link 1.Continuously rotating axes cannot be monitored.Drive units cannot be shared, for instance between positioner axes.Electronic Position Switches uses only passive monitoring, that sets output signalsbut does not stop the robot.

Supported robotsThe following robot families are supported by Electronic Position Switches:

• IRB 140• IRB 260• IRB 660• IRB 1600• IRB 2400• IRB 2600• IRB 4400• IRB 4600• IRB 5400• IRB 6620• IRB6620LX• IRB 6640• IRB 6660• IRB 6650S• IRB 7600

Other robot models are not supported.Electronic Position Switches cannot be used for parallel robots, such as IRB 360.

Supported additional axesBasically the option Electronic Position Switches only supports ABB track motionunits. Non ABB track motion units and non ABB positioners may be supported byElectronic Position Switches if the customer configures the appropriate parameters.Electronic Position Switches only supports additional axes that are single axismechanical units. For example, two axes positioners cannot be supported.Further, there are always the following upper and lower work area limitations:

• Track unit length (arm side) max ± 100 m• Rotating axis (arm side) max ± 25 700 degrees or ± 448 radians

On the motor side there is also a limitation of ± 10 000 revolutions.

Continues on next page14 3HAC027709-001 Revision: J ongoing



Continued

RequirementsRobust monitoring function in Electronic Position Switches requires correct settingsof payload and additional axes, since this will affect the calculated accepted servolag. Please also note that external forces applied on the manipulator can cause anegative influence on the monitoring functions, since the servo lag might differfrom the calculated values, due to such external forces.

DANGER

An Electronic Position Switches configuration must always be validated to verifythat the desired safety is achieved. If no validation is performed, or the validationis inadequate, the configuration cannot be relied on for personal safety.



Continued

1.2 Terminology

About these termsSome words have a specific meaning when used in this manual. It is important tounderstand what is meant by these words. This manual’s definitions of these wordsare listed below.

Term list

DefinitionTerm

Passive monitoring with signaling function only.Monitoring

Safe for a person to be in an area.Occupationally safe

Safe for the machinery but not safe for persons to enter thearea.

Operationally safe

Dual monitored digital input.Safe input

Dual monitored digital output.Safe output

A safety board used with IRC5. Can be an Electronic PositionSwitch safety controller or a SafeMove safety controller.

Safety controller

Same as complementary signal. The logical value of onechannel is the complement of the other in a dual channel signal.

Antivalent signal

The logical value of one channel is equivalent to the other ina dual channel.

Equivalent signal


1 Introduction1.2 Terminology

2 Electronic Position Switches functions2.1 Monitor Axis Range

Monitor Axis RangeMonitor Axis Range is a monitoring function that determines if all axes are withinthe defined ranges. Safe digital output signals are used to indicate when all axesare within their defined ranges.

Note

Monitor Axis Range can only safely determine that the monitored axes are withinthe defined ranges (i.e. when the output signal is high). It is not safe to assumethat an axis is outside the defined range when the signal is low.

Monitoring functionalityThe positions of the axes can be monitored as follows:

• Up to five safe digital output signals can be defined.• For each safe digital output signal, a combination of up to seven axis ranges

can be defined.If an axis is outside its defined range, a safe digital output signal goes low. Eachset of axes can be allocated an output signal.

Borderline positionsIn very rare cases an error message (elog 20473) might be presented if the robotis stopped for a longer time (> 40 min) in a position exactly on the border of thedefined range due to internal design.

SettingsThe following settings need to be configured for Monitor Axis Range:

• Axis ranges (degrees or mm) for each axis.• Assignment of safe digital output for each set of axis ranges.• Invert axis for each axis.• Allow inside for each set of axis ranges.

LimitationsContinuously rotating additional axes cannot be monitored. If an additional axis iscontinuously rotating, it must not be configured for monitoring.If you have a continuously rotating robot axis (using independent axis for axis 4or 6) monitoring is not used for that axis. Other robot axes can still be monitored,but the independent axis must be specified in the configuration (see Selectmechanical unit on page 40).




Example of rangesThis example shows a robot with defined axis ranges for axes 2 and 3 in threedifferent positions. The function Monitor Axis Range monitors that axis 2 is withinrange x2 and that axis 3 is within range x3.In positions A and B, all monitored axes are within the defined ranges. In positionC, axis 3 is not within the defined range.

xx0600003331

Defined axis position range for axis 2.x2

Defined axis position range for axis 3.x3

Robot position A. Both axis 2 and axis 3 are within the defined ranges.A

Robot position B. Both axis 2 and axis 3 are within the defined ranges.B

Robot position C. Axis 2 is within the defined range but axis 3 is not within itsdefined range.

C

In this example, if range x2 and x3 are defined for the same signal, this signal willgo low if any of the axes is outside its defined range.Note! The ranges define axis angles, not the position of the TCP. In robot positionC, the TCP is still within what seems to be a safe range, but axis 3 is outside itsdefined range.




Continued

Example of usageDefine two ranges for axis 1 and let a safety PLC decide when the axis must beinside range A and when it must be inside range B.

Safetyinstructions

A

B

xx0700000144

Range for axis 1 defined for safe output signal 1.A

Range for axis 1 defined for safe output signal 2.B



Continued

2.2 Cyclic Sync Check

Cyclic Sync CheckCyclic Sync Check is a function that makes sure that the robot calibration is correctby using a physical switch.

FunctionalityThe robot must move to a safe sync position to ensure that the safety controllerand the robot controller are synchronized. The safe sync position is defined duringconfiguration and stored in the safety controller.With a defined interval (sync cycle time), the robot must move to the safe syncposition and activate a switch. If the sync check is not performed within the synccycle time, all output signals will go low (which should stop the robot if implementedcorrectly). A warning is shown on the FlexPendant a pre-defined time (pre-warningtime) before the sync cycle time has passed.When the switch is activated, the safety controller assumes that the robot revolutioncounters are correct. It also calculates the arm position from the motor positions,the gear ratio, and its internal revolution counter. If the position matches the storedsync position within half a motor revolution, then the synchronization is assumedto be correct.If the synchronization is correct, the safety controller then sends elog 20452 to therobot controller, telling that the safety controller is synchronized to its mechanicalunits, and continues with its regular operation.

SettingsThe following settings need to be configured for Cyclic Sync Check:

• Sync cycle time, 12-720 hours.• Pre-warning time, 1-11 hours.• Angles and positions of robot (and additional axes) at sync position.

How to define these settings is described in Set sync position on page 47.

Virtual output signals from main computerA virtual output signal is set when the prewarning time has expired. Another virtualsignal will correspond to the sync status. See also .

Limitations• The safe sync position must be within reach for the robot. It must not be a

singularity, that is all six axis must have unique positions.

Related informationSynchronization guidelines for Cyclic Sync Check on page 61.


2 Electronic Position Switches functions2.2 Cyclic Sync Check

2.3 Software Sync Check

Software Sync CheckSoftware Sync Check is a function that makes sure that the robot calibration iscorrect. If wrong robot calibration easily can be detected by the application, thenit is generally possible to execute the synchronization check by software. In thatcase it is done when required, not cyclically.

FunctionalitySoftware synchronization is performed by running the service routineSoftwareSync. How to run the service routine is described in sectionUse serviceroutine to perform synchronization on page 63.If the safety controller has not been synchronized before, and the synchronizationattempt was unsuccessful, the user has to check and confirm on the FlexPendantthat both the robot controller and the safety controller have the same opinion aboutrobot axes positions.

SettingsThe following settings need to be configured for Software Sync Check:

• Angles and positions of robot (and additional axes) at sync position.How to define these settings is described in Set sync position on page 47.

Virtual output signals from main computerA virtual output signal corresponds to the sync status. See Virtual signals onpage 67.

LimitationsSoftware Sync Check is only available for EPS board 3HAC026271-001 revision06 or later.

Related informationSynchronization guidelines for Software Sync Check on page 63.


2 Electronic Position Switches functions2.3 Software Sync Check

2.4 Control Error Supervision

Control Error SupervisionControl Error Supervision is a function that monitors the difference between thereference value and the measured value of the motor position of each axis. ControlError Supervision is required to ensure the accuracy in the monitoring functions.

Supervision functionalityThe control error (servo lag) is the absolute value of the difference between thereference value and the measured value of the motor position of each axis.Control Error Supervision is activated automatically after the safety controller hasbeen synchronized with the robot position.When Control Error Supervision trips the following happens:

• All output signals go low.• An elog message (20454) is sent to the robot controller.• A new synchronization is required.

Illustration of control error

en0700000723

Function activationControl Error Supervision is always active. It can only be relaxed by OperationalSafety Range.

Dependencies to other functionsIf Operational Safety Range is active, then Control Error Supervision is relaxedaccording to user definitions.

SettingsControl Error Supervision settings are only required for additional axes.For additional axes, the following settings need to be configured:

• Servo Lag• Servo Delay Factor

How to define these settings is described in Configure additional axis on page 41.

Related informationOperational Safety Range on page 23.


2 Electronic Position Switches functions2.4 Control Error Supervision

2.5 Operational Safety Range

Operational Safety RangeOperational Safety Range relaxes the monitoring of the servo lag if ALL configuredaxes are within a defined axis range.

FunctionalityOperational Safety Range is a special definition of an axis range that relaxes theControl Error Supervision (servo lag) to a higher value if ALL configured axes arewithin (inclusive) the defined axis range. It can be used, for instance, in machinetending, when the servo loop gain is reduced (soft servo) or during Force Control.It is also useful when external forces are applied to the robot.If the robot is within the defined range, then the safety level is considered to beoperationally safe rather than occupationally safe. That means it is not safe forpersonnel to be in the range defined for Operational Safety Range.To activate the relaxed control error, all of the following conditions must be true:

• The reference values for ALL configured axes must be within the rangedefined by the Operational Safety Range function.

• The measured values for ALL configured axes must be within the rangedefined by the Operational Safety Range function.

The function is automatically activated after the safety controller has beensynchronized with the robot position. No dynamic activation is possible.Up to 7 axes can be monitored simultaneously.

SettingsThe following settings need to be configured for Operational Safety Range:

• Axis range definition for each axis, physical position in degrees or mm onarm side.

• Permissible control error for each axis, in degrees or mm on arm side.The definition of axis range consists of:

• Minimum axis limit (degrees or mm).• Maximum axis limit (degrees or mm).

How to define these settings is described in Configure the Operational SafetyRange on page 47.

Related informationControl Error Supervision on page 22.



2 Electronic Position Switches functions2.5 Operational Safety Range

ExamplesThis example shows a robot with defined axis ranges for axes 2 and 3. The functionOperational Safety Range monitors if axis 2 is within the range x2 and if axis 3 iswithin the range x3. As long as the measured values and the reference values forboth axes are within these ranges, the Control Error Supervision is relaxed.

xx0600003319


2 Electronic Position Switches functions2.5 Operational Safety Range

Continued

3 Installation3.1 Hardware installation

3.1.1 I/O connector data

Location

BC

D

E

A

1

14

xx0600003209

I/O Connector on the safety controllerA

Plug contactB

Power supplyC

5 safe outputs (10 signals)D

Sync switch (dual signal)E



3 Installation3.1.1 I/O connector data

I/O connector pin descriptions

en0600003222

DescriptionSignalPin

Plus pole for power to the I/O connector.Power input 24 V1

Minus pole for power to the I/O connector.Power input 0 V2

Monitored high side output signal for Monitor Axis Range. Thesignals are configured in the EPS Configuration Wizard.

MAR signal 1A3

Switches on or off 24 Volts supplied by the power input (pin 1 and2).

-"-MAR signal 1B4

-"-MAR signal 2A5

-"-MAR signal 2B6

-"-MAR signal 3A7

-"-MAR signal 3B8

-"-MAR signal 4A9

-"-MAR signal 4B10

-"-MAR signal 5A11

-"-MAR signal 5B12

Input signal for synchronization check.Sync switch inputsignal 1A

13A synchronization pulse is defined by this signal connected toground (0 V).When there is no synchronization pulse, this signal should beopen or connected to 24 V.

Input signal for synchronization check.Sync switch inputsignal 1B

14A synchronization pulse is defined by this signal connected to 24V.When there is no synchronization pulse, this signal should beopen or connected to ground (0 V).

Voltage and current data

Max valueMin valueDescription

26.4 V21.6 VVoltage for I/O power supply

+2 V-3 VVoltage for low value on digital input




Continued

Max valueMin valueDescription

+27 V+21 VVoltage for high value on digital input

0.8 A-Max output current by one digital output

2.2 A-Sum of output current by all digital outputs

Signal redundancyAll output signals have redundancy as a safety measure, i.e. output signal 1A andoutput signal 1B should always be identical. If they differ for more thanapproximately 100 ms, there is an internal error. Always handle this error bystopping all mechanical units.The input signal used for sync check uses redundancy where input signal 1A isthe inverted signal of input signal 1B. Here you have the choice of only using inputsignal 1B, but this must be defined in the EPS Configuration Wizard.



Continued

3.1.2 I/O signals

Using the input signalThe safety controller requires an input signal for Cyclic Sync Check. Connect asignal from a sync switch. When the robot is in its sync position, pin 14 should beset high and pin 13 should be set low. If dual channel wiring is not used, connectonly pin 14.Principle for sync switch connected to the safety controller using dual input signal:

en0600003304

Principle for sync switch connected to the safety controller using single input signal:

en0600003305

Additional axisWhen synchronizing an additional axis and a robot, use a separate sync switchfor the additional axis and connect it in series with the sync switch for the robot.

en0600003312

Exception: If the additional axis is a track motion or a robot-held tool, it can usethe same sync switch as the robot. These types of additional axes can be treatedas a 7th robot axis. Note that this makes it more complicated to find a non-singularitysync check position.



3 Installation3.1.2 I/O signals

Using the output signalsThe safety controller has 5 dual output signals that indicate if all axes are insidethe defined range. When performing the installation, it is the responsibility of theinstallation personnel to make sure that these signals will stop the robot if an axisgoes out of its allowed range. Connect the output signals to a PLC, or similarequipment, that can stop the robot when a signal goes low.The safety controller works with redundancy (dual processors, dual output signals,etc.). Safe robot behavior (inside defined range) is indicated by high value on theoutput signal, so that a power failure will be interpreted as unsafe and stop therobot.Make sure that the output signals from the safety controller are connected in sucha way that the redundancy is preserved (if one of the dual signals goes from 24 Vto 0 V, the system should stop). Also make sure that a low signal always representsthe safe state that stops the robot, so that a power failure on the PLC also stopsthe robot.What the different output signals indicate is defined in the EPS ConfigurationWizard, see EPS Configuration Wizard on page 39.

Test pulses on output signals

Test pulses during start-upAt the beginning of each system start-up there are test pulses on the outputspresent. This must be considered at installation and commissioning so that it isnot interpreted as an axis being outside its defined range.

Test pulses during operationDue to safety reasons there are test pulses on the output signals during operation.The pulses have a maximum length of 2 ms and are only present when the outputsare high. This must be considered at installation and commissioning so that it isnot interpreted as an axis being outside its defined range. Make sure the PLC orsafety relay does not react on pulses shorter than 2 ms.

Max inductive loadThe inductive load on the outputs must be less than 200 mH.




Continued

Principle for connecting signals to PLC

en0600003223

Using a safety relayAn output signal from the safety controller can be connected to a safety relay whichcan stop the robot immediately. This can be implemented by letting the safety relayopen the circuit for, for example, the general stop signal 1 and 2 on the panel boardof the IRC5 controller.

en0600003306




Continued

Connect to Auto Stop on the panel boardA signal from a safety relay or a PLC can be connected to the Auto Stop signal ofthe panel board in the IRC5 controller. If the Auto Stop circuit is open, the robotcannot move in auto mode. However, it is still possible to move the robot in manualmode.

en0600003336

Connect to General Stop on the panel boardA signal from a safety relay or a PLC can be connected to the General Stop signalof the panel board in the IRC5 controller. If the General Stop circuit is open, therobot cannot move either in auto or manual mode.Note that when the General Stop circuit is open, there is no way of jogging therobot back to the defined range. Therefore, using the General Stop signal requiresan additional switch to close the circuit while jogging the robot back inside thedefined range. For safety reasons, the switch used to override the relay needs tobe of safety level category 3 or higher according to EN954−1 (safety level isdependant of the required safety level for the installation). Use, for example, adead man’s handle.

en0600003337



Continued

3.1.3 Power supply

Use IRC5 ground or isolate the I/OThe safety controller requires one system power supply and one I/O power supply.These two power supplies must have a common ground potential.The I/Os of the safety PLC must either have the same ground potential as the safetycontroller (i.e. as the IRC5 cabinet), or the I/Os of the safety PLC must begalvanically isolated from the safety controller. This can be achieved in differentways as seen in the examples below.

Example with common groundIn this example the I/Os of the safety controller, the sync switch, and the safetyPLC has a common ground potential. The ground of the I/O power supply isconnected to the ground of the system power supply (i.e. the ground of the IRC5power supply).This setup is usable up to a distance of 30 meters between the IRC5 cabinet andthe safety PLC.

IRC5

24 V

24 V

Safety controller

System powerinput

MAR 1-5

I/O power input

Isolated syncswitch

Safety PLC

Safety I/O

Power inputIRC5 ground IRC5 groundDI

System power

I/O power

xx1200000201

For a single cabinet IRC5 controller, the I/O power supply can be an internal powersupply located in the IRC5 cabinet. For a dual cabinet IRC5 controller, an externalpower supply needs to be used.



3 Installation3.1.3 Power supply

Example with isolated I/OIn this example the I/O connector of the safety controller is isolated from the safetyPLC with optocouplers. The ground of the safety controller (i.e. the ground of theIRC5 power supply) is isolated from the ground of the safety PLCThis setup is usable up to a distance of 30 meters between the IRC5 cabinet andthe safety PLC.

IRC5

24 V

24 V

Safety controller

System powerinput

MAR 1-5

I/O power input Isolated syncswitch

Safety PLC

Safety I/O

IRC5 ground

External groundDI

System power

I/O power

Optocouplers

xx1200000202

Example with safety busA solution with a safety bus will automatically solve the problem of galvanic isolationfrom the PLC. It will also allow the distance between the IRC5 and PLC to be greaterthan 30 meters. The maximum distance for this solution depends on the safetybus used by the PLC.

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3 Installation3.1.3 Power supply

Continued

3.1.4 SMB connection for additional axis

About SMB connectionsFor Electronic Position Switches, you can only use SMB link 1. This means thatyou can only connect one additional axis. The additional axis must be connectedto the robot SMB.

Connect additional axis directly to the robotConnect the SMB cable from the additional axis to the SMB connection on therobot. By connecting the additional axis here, it will be read as axis 7 on the SMBcable from the robot to the safety controller.

xx0600003366

SMB connection on robot base, where the additional axis can be connected asthe 7th axis in SMB link 1.

A


3 Installation3.1.4 SMB connection for additional axis

3.2 Software installation

3.2.1 Installing required software

Note

RobotStudio must be of the same version or later than the RobotWare used.

Install RobotStudioThe EPS Configuration Wizard is installed with RobotStudio. Install RobotStudioas described in Operating manual - Getting started, IRC5 and RobotStudio.RobotStudio can be installed with the options Minimal or Full, and the EPSConfiguration Wizard is installed with either of these installation options. The EPSConfiguration Wizard is available in the Online tab of RobotStudio.

Create a robot systemCreate a robot system as described in Operating manual - Getting started, IRC5and RobotStudio. Use a drive module key that gives access to Electronic PositionSwitches and select the option 810-1 Electronic Position Switches.

Configure IRC5Configure the robot system (coordinate systems, tools, work objects, robot celllayout, etc.) before configuring Electronic Position Switches.


3 Installation3.2.1 Installing required software


4 Configuration4.1 Create a safety user

Why do you need a safety userConfiguring Electronic Position Switches is normally done initially and then neverchanged (until the robot is used for a different purpose). It is vital that the safetyconfiguration is not changed by unauthorized personnel. It is thereforerecommended to have specific safety users who are granted the right to configureElectronic Position Switches.

PrerequisitesYou must have created a robot system with the option 810-1 Electronic PositionSwitches. How to create a system is described inOperating manual - RobotStudio.

How to create a safety user

Action

Request write access from RobotStudio:1In the Online browser, right-click on the controller and select Request Write Access.If in manual mode, confirm the write access on the FlexPendant.

Start UAS Administrative Tool:2In the Online browser, right-click on the controller and select Authenticate and thenEdit User Accounts.

Select the tab Groups.3

Click Add and type a name for the group, e.g. "Safety".4

Select the group you have created and select the check boxes for the controller grants:• Execute program• Safety Controller configuration• Write access to controller disks

The group may have more grants, but these are the minimum required.

5

Select the tab Users.6

Click Add and type a name for the user, e.g. "SafetyUser", and a password for theuser.

7

Select the user you have created and check the group you previously created, e.g.Safety.

8

The user may belong to more groups.

Click OK.9

Restart the controller.10

Tip

Create different user groups as described in Operating manual - RobotStudio,sectionManaging the user authorization system. Make sure that one administratorhas the grantManage UAS settings and that the regular users (operators, Defaultuser, etc.) do not have the grants Safety Controller configuration, Write accessto controller or Manage UAS settings.




Granting right to perform software synchronizationThere must always be a safety user with the right to everything that has to do withthe safety controller. The safety user can always perform a softwaresynchronization. If you want someone else to be allowed to perform a softwaresynchronization, this grant can be given to them.

Action

Request write access, open the UAS Administrative tool and select tab Groups asdescribed in How to create a safety user on page 37.

1

Select the group that should have the grant (for example Operator).2

Select Application grants in the drop-down box.3

Select the check box for SafeMove/EPS software sync service routine.4

Click OK.5



Continued

4.2 EPS Configuration Wizard

What is the EPS Configuration WizardIn the EPS Configuration Wizard you configure the ranges and tolerances used bythe functions of Electronic Position Switches.

PrerequisitesOnly a safety user is allowed to download a configuration. A safety user must becreated before configuring Electronic Position Switches (see Create a safety useron page 37).

Start the EPS Configuration Wizard

Action

In RobotStudio’s Online browser, right click on the controller and select Authenticateand then Login as Different User.

1

Select the safety user, e.g. SafetyUser. Type the password and click Login.2

Select the controller you wish to configure. In the Online browser, right click on thecontroller and select Safety Configuration and then EPS Wizard.

3

In the menu Tools, select EPS Configuration Wizard.

Click Next.4

Select drive moduleSelect if you are configuring a single robot system or a MultiMove system.If you configure a MultiMove system you must select which drive module you wantto configure. The configuration procedure must be repeated for each drive module.For information about configuration of a MultiMove system, see Configuration forMultiMove on page 54.

en0600003210

Click on Next.



4 Configuration4.2 EPS Configuration Wizard

Select configuration formatIn the EPS Wizard you need to select the configuration format. Version 1.1.0 is thestandard format and the recommended selection, which also appears as a defaultsetting in the dialog box. In some rare cases, for example when you receive a newEPS unit as a replacement of an old unit that is supporting the version 1.0.0 format,select the version 1.0.0.

Select mechanical unitCheck the mechanical unit you want to configure.If you want to configure a robot and an additional axis, select both. There is amaximum of 7 axes per drive module, so if you configure a robot you cannotconfigure more than one additional axis for that drive module.If one axis is used as an independent axis, there can be no monitoring of that axis.Under Independent Axis, you have the following choices regarding the optionIndependent Axes [610-1]:

• None: Monitoring possible on all axes, but you cannot use the optionIndependent Axes.

• Axis_4: Monitoring is possible on axes 1-3, but not on axes 4-6. You cannow use the option Independent Axes for axis 4 and/or axis 6.

• Axis_6: Monitoring is possible on axes 1-5, but not on axis 6. You can nowuse the option Independent Axes for axis 6, but not for axis 4.

It is possible to open an existing configuration and make modifications to it. To getthe current configuration from the controller, click on Get from controller. To geta configuration that is previously saved to file, click on Load from file.

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Click on Next.




Continued

Configure additional axisIf an additional axis was checked in the previous step, specify configurationparameters for the additional axis (many of them are the same as some systemparameters defined in the topic Motion):

• Logical Axis - see system parameter Logical Axis in type Joint.• Servo Lag - calculated lag (in radians on motor side) for the additional axis.• Servo Delay - calculated delay factor (number of 4 ms units) when moving

the additional axis.• Motor Commutation - see system parameter Commutator Offset in type

Motor Calibration.• Link - see system parameter Measurement Link in type Measurement

Channel.• Node - see system parameter Measurement Node in type Measurement

Channel.• Board Position - see system parameterBoard Position in typeMeasurement

Channel.• Upper Limit - upper limit of the axis (in mm or degrees on arm side, depending

on if Rotating Move is checked). See system parameter Upper Joint Boundin type Arm, but notice that Upper Joint Bound is specified in radians onmotor side.

• Lower Limit - lower limit of the axis (in mm or degrees on arm side, dependingon if Rotating Move is checked). See system parameter Lower Joint Boundin type Arm, but notice that Lower Joint Bound is specified in radians onmotor side.

• Transmission Joint - see system parameter Transmission Gear Ratio in typeTransmission.

• Rotating Move - should be checked for rotational additional axis and notchecked for linear additional axis.

en0600003212




Continued

Click on OK.

Note

Accurate values for the additional axis are important to avoid problems with toolarge servo lag.

Configure motor calibration offsetsThe first time you configure a new robot you must provide the motor calibrationoffsets. These values are required to achieve a high precision in the monitoring ofthe axes positions.The calibration offset parameters are found in the system parameter CalibrationOffset in type Motor Calibration, topic Motion.To set the motor calibration values, check the box Enable Calibration OffsetConfiguration and then press the button Get From Controller or enter the values.If the motor calibration values have already been set and downloaded to thecontroller, leave Enable CalibrationOffset Configuration unchecked and continue.

en0600003213

Click on Next.

Note

Observe that the motor calibration values need to be set both for the robotcontroller and for Electronic Position Switches. Therefore this dialog must befilled in even if the calibration offsets already are set in the robot controller. Everytime the calibration values are changed in the robot controller they also need tobe changed in the EPS Configuration Wizard. Also remember to download thecalibration file as described in EPS Configuration Wizard on page 39.




Continued

Configure the Monitor Axis RangeYou can define up to five different safe output signals. For each signal you candefine a range for each axis. Select output signal to configure by clicking on thecorresponding tab.For each axis where you want to define an axis range, check the box Enable andset the range by dragging the markers along the slide bar. The defined range ismarked green on the scale.By checking the box Invert for an axis the range between the markers is nowoutside the defined range, shown as red on the scale.The output signal is high when all axes are within the defined range, and low whenone (or more) axis is outside.

en0600003214

Click on Next.

Inverted functionBy checking Invert function, a robot position is only considered hazardous if allaxes are inside their defined ranges.Not inverted axis ranges and not inverted function:




Continued

If neither the axis ranges or the function is inverted, the safe zone (where no signalis set low) is when all axes are inside their defined ranges. This safe zonecorresponds to the white area in the right picture below.

xx0700000436

Not inverted axis ranges and inverted function:If the axis ranges are not inverted, but the function is inverted, the safe zone (whereno signal is set low) is everywhere except where all axes are inside their definedranges. This safe zone corresponds to the white area in the right picture below.

xx0700000438

Inverted axis ranges and not inverted function:If the axis ranges are inverted but not the function, the safe zone (where no signalis set low) is when all the axes are inside their defined ranges, i.e. when none of




Continued

the axes are inside the undefined range in the middle. This safe zone correspondsto the white area in the right picture below.

xx0700000437

Inverted axis ranges and inverted function:If the axis ranges are inverted and the function is inverted, the safe zone (whereno signal is set low) is when one of the axes is inside the undefined range in themiddle. This safe zone corresponds to the white area in the right picture below.

xx0700000439

Example of how to use the inverted function:A robot may have two working areas defined by axis ranges for axis 1 (MAR1 andMAR2). To be able to move between these two working areas, axis 1 may be inthe range in between, under the condition that axis 2 is pointing up or backwards.By defining MAR3 as axis one being between MAR1 and MAR2 and axis 2 pointing




Continued

forward, and inverting the function, the MAR3 signal will go low if both axis 1 andaxis 2 are pointing straight forward.

Invert function

xx0700000443

xx0700000442




Continued

Configure the Operational Safety RangeIf using soft servo, the servo lag can easily exceed the limits for the function ControlError Supervision. In this step of the wizard you can set axis ranges where thetolerance for Control Error Supervision is higher.For each axis, set the range where the tolerance should be higher (the red area).Also set how high the tolerance should be. The tolerance (in degrees on arm side)is specified in Tolerance.

en0600003215

Click on Next.

Set sync positionJog the robot to the synchronization position used by Cyclic Sync Check or SoftwareSync Check and click on Get actual position.Sync Check Cycle defines the maximum allowed time (in hours) betweensynchronization checks.Before the cycle time has expired, a warning will be shown on the FlexPendant.Pre-warning defines how long before the cycle time is up this warning shouldoccur.When the cycle time has expired without a sync check, all output signals will golow.If a dual input signal is used for the synchronization check, connected to pin X10.5and X10.6 on the I/O connector, select Dual Channel in the drop-down box. If asingle input signal is used, connected to pin X10.6, select Single Channel. If the




Continued

Software Sync Check function is used, select Software Synchronization (onlyavailable for EPS board 3HAC026271-001 revision 06 or later).

en0600003216

Click on Next.

Tip

Save the synchronization position as a robtarget in your RAPID program. Also,in the RAPID program, create a timer and program the robot to perform asynchronization. Use a shorter cycle than the configured Check Cycle minusPre-Warning to avoid warnings on the FlexPendant.

Save and download to controllerFrom the last dialog in the wizard, you can:

• Save the motor calibration file. If no motor calibration has been performed,this button is grayed out.

• Save the safety configuration file.• Download the motor calibration to the controller.• Download the safety configuration to the controller.




Continued

en0600003217

Save motor calibration fileSave the motor calibration file so that you can load the values later, if required:

1 Click on Save to File under Motor Calibration. If no motor calibration hasbeen performed, this button is grayed out.

2 Select a file name and location for the file.

Save safety configuration fileSave the safety configuration file so that you can load the values later, if required:

1 Click on Save to File under Safety Configuration.2 Select a file name and location for the file.

Download motor calibration to controllerDownload the motor calibration to the controller:

1 Click on Download to Controller under Motor Calibration. If no motorcalibration has been performed, this button is grayed out.

2 A dialog informs you when the download is complete. Click OK.

Download safety configuration to controllerDownload the safety configuration to the controller:

1 Click on Download to Controller under Safety Configuration.2 A report of the safety configuration is shown, see picture below. The report

can be saved by clicking the Save button. By default the report is saved inthe folder C:\Documents and Settings\Username\Local Settings\ApplicationData on the computer where EPS Configuration Wizard is running. The reportcan be printed by right-clicking and selecting Print (it is recommended toprint the report since it should be used when validating the configuration asdescribed in Validate the configuration on page 58). Click OK to close thereport.

3 A dialog informs you when the download is complete. Click OK.4 A PIN code for the configuration file is shown (which is also included in the

safety report). Write this PIN code down. You will need it when activating theContinues on next page



Continued

safety configuration on your system, see Activating the safety configurationon page 56.

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Finish the EPS Configuration Wizard1 Click on the button Finish.2 Restart the controller (warm start).



Continued

4.3 Configuration for robots with non-zero calibration position

Calibration position axis anglesSome robots have calibration positions with one or more axis angles that is notzero.

xx0900000217

Calibration marks, axis 3A

Calibration position, axis 1B

Examples of non-zero calibration positions:

Calibration position values

Axis 6Axis 5Axis 4Axis 3Axis 2Axis 1Robot type

0°0°0°58.7°0°40°IRB 5400-12 - Slim arm

0°0°0°60°0°40°IRB 5400-22 - Process arm

To find the exact axis angles for a robot, look at the system parameter CalibrationPosition in topic Motion, type Arm.

Effects on the EPS configurationFor robots with non-zero calibration position it is necessary to perform manualcorrections during the EPS configuration. Follow the description in EPSConfigurationWizard on page39 but adjust axis limits and sync position accordingto the following descriptions.



4 Configuration4.3 Configuration for robots with non-zero calibration position

Adjust axis limitsAdjust the axis limits by subtracting the calibration offset value from the real axislimits you want to set up.

ExampleA robot has a calibration position with a 40° calibration offset for axis 1.

Configured axis limitDesired axis limitLimit

10° - 40° = -30°10°Low

75° - 40° = 35°75°High

en0900000220




Continued

Adjust the sync positionAdjust the axis degree values of the sync position by subtracting the calibrationoffset.

ExampleA robot has a calibration offset of 40° for axis 1 and 60° for axis 3.Click on Get actual position and get the following values:

en0900000221

Adjust the sync position by subtracting 40° from axis 1 and 60° from axis 3:

en0900000222



Continued

4.4 Configuration for MultiMove

Configuration file corresponding to drive moduleIn a MultiMove system there is one safety controller for each drive module thatuses Electronic Position Switches. A configuration file must be downloaded toeach safety controller. It is important that the configuration file downloaded to asafety controller contains the configuration for those mechanical units controlledby that drive module.

MultiMove system with 4 safety controllers

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Safety controller 1 placed in the controller cabinet. Used to monitor robot 1 andadditional axis 1.

A

Safety controller 2 placed in drive module 2. Used to monitor robot 2.B

Safety controller 3 placed in drive module 3. Used to monitor robot 3.C

Safety controller 4 placed in drive module 4. Used to monitor robot 4 and addi-tional axis 2.

D

Controller cabinetE

Drive module 2F

Drive module 3G

Drive module 4H

Robot 1I

Robot 2J

Robot 3K

Robot 4L

Additional axis 1M

Additional axis 2N



4 Configuration4.4 Configuration for MultiMove

How to configure EPS for MultiMoveWhen configuring a MultiMove system, follow the same procedure as describedin EPSConfigurationWizard on page39 for the first safety controller (in the exampleabove: robot 1 and additional axis 1). When the configuration file is downloadedto the controller, click on Finish and then start the EPS Configuration Wizard again.Repeat this procedure once for every safety controller and make sure the selecteddrive module corresponds to the mechanical units configured.

en0600003311

You will get one unique PIN code for each safety configuration file. Write thesePIN codes down.

Note

Make sure that, for every configuration file, the configured mechanical unitsbelong to the selected drive module. The EPS Configuration Wizard will allowyou to configure any mechanical unit for any selected drive unit, but the resultwill be an unexpected behavior.


4 Configuration4.4 Configuration for MultiMove

Continued

4.5 Activating the safety configuration

PrerequisiteBefore activating the safety configuration you must create the safety configurationfile and remember the PIN code for that file (see EPS Configuration Wizard onpage 39).

Activation procedure

Action

When a safety configuration is downloaded to your robot system, the controller mustbe restarted (warm start).

1

When the controller starts up, an elog message (20266) will ask for a safety controllerPIN code. Acknowledge this message.

2

Change user on the FlexPendant:1 On the ABB menu, select Log off.2 Tap Yes to confirm.3 Select the safety user, type the password and tap on Login.

3

Make sure the controller is in manual mode.4

On the FlexPendant:1 On the ABB menu, tap Control Panel and then Safety Controller.2 Tap the line and type the PIN code for the safety configuration file (see EPS

Configuration Wizard on page 39). Tap OK.3 For a MultiMove system, enter one PIN code for each configuration file.4 Tap OK.

en0600003332

5



4 Configuration4.5 Activating the safety configuration

Action

When the PIN code is entered, a dialog will tell you if the PIN is correct. Tap Restartin this dialog and the controller will restart.

6

If you typed an incorrect PIN code, the controller will restart anyway. Then you muststart over from step 2 of this procedure.

When the controller starts up, an elog message (20451) will say that a synchronizationis required. Acknowledge this message.

7

Perform a sync check. Note that the output signals are low until the sync check isperformed. This means that if you have connected to the Auto Stop on the panel board,sync check must be performed in manual mode. If you have connected to GeneralStop, the circuit must be closed in a safe way during the sync check. See Connect toAuto Stop on the panel board on page 31 and Connect to General Stop on the panelboard on page 31.When the sync check is performed, an elog message (20452) will say that the robotis synchronized. The Electronic Position Switches functionality is now active.

Safety configuration active until cold startOnce activated, the safety configuration is constantly active. Neither warm startnor i-start of the controller will affect the safety configuration. However, a cold startof the controller will remove all safety configurations.


4 Configuration4.5 Activating the safety configuration

Continued

4.6 Validate the configuration

DANGER

An Electronic Position Switches configuration must always be validated to verifythat the desired safety is achieved. If no validation is performed, or the validationis inadequate, the configuration cannot be relied on for personal safety.

Tip

Do the following checks before you start the validation procedure:1 Check the I/O signals according to section I/O connector data on page 25.2 Create a safety user in the user authorization system and log in as a safety

user.3 Carry out the synchronization procedure and connect the sync switch

according to description in section I/O connector data on page 25.4 Set up the synchronization position in the EPS Configuration Wizard. Also

carry out a calibration offset.5 Run the service routine for the function Cyclic Break Check.6 Start the validation procedure.



4 Configuration4.6 Validate the configuration

About the validationThe safety configuration must be validated by the customer. This validation mustbe performed every time a safety controller is configured. It is recommended thatthe ABB Safety Configuration Report is printed and used as a formal documentfor the verification. The document has rows where dates and signatures shouldbe written when the configuration is verified.

en0700000103

How to validateMove the robot in and out of the configured zones and make sure all signals behavethe way they are supposed to.


4 Configuration4.6 Validate the configuration

Continued

4.7 Viewing the configuration on the FlexPendant

Accessing the configuration information

Action

On the ABB menu, tap Control Panel and then Safety Controller.1

Tap the line for the safety controller you wish to view.2

Tap View.3

Configuration presentation

en0900001052


4 Configuration4.7 Viewing the configuration on the FlexPendant

5 Synchronization5.1 Synchronization guidelines for Cyclic Sync Check

Dual channel or single channelVerify that the right type of synchronization (dual channel or single channel) wasselected in the configuration.See Set sync position on page 47.

Uniquely defined positionThe robot position for the sync check must be chosen so that the position of therobot axes are unambiguously defined. One way to make sure the sync checkposition is well-defined for all axes is to use the instruction MoveAbsJ to move tothe sync position. See Technical referencemanual - RAPID Instructions, Functionsand Data types.Note that the sync position should be within the axis ranges configured for MonitorAxis Range to avoid that the robot stops on the way to the sync position.

Small sync switch surfaceFor physical synchronization, the sync switch surface that the robot touches mustbe small. The surface of the tool touching the sync switch must also be small. Ifany robot axis moves one motor revolution, the robot must be out of reach for thesync switch.

Always activate sync switch in the same wayFor physical synchronization, always use the same tool. The robot should alwaystouch the sync switch with the same point on the tool.

Create RAPID program for synchronizationCreate a RAPID program to perform a synchronization.This can be initiated froma PLC or the main RAPID program. Perform the synchronization when the digitaloutput signal PSC1CSPREWARN goes high. The PSC1CSPREWARN signal isonly activated when Dual channel or Single channel synchronization has beenselected in the configuration. When Software synchronization has been selected,it is only necessary to do a synchronization if the safety controller or the robotcontroller has become asynchronous.Write the program so that the robot first goes to a position close to the sync switchand then approach it slowly from the desired direction. If the approach is too fast,the accuracy of the robot position may be too low.

ExampleIn a system module elog 20470 is caught and an output signal is set. This signalcan be used by a PLC or a RAPID program.

MODULE SYNCINIT (sysmodule)

LOCAL VAR intnum irSyncPreWarn;




LOCAL TRAP tpSyncPreWarn

setDO doSyncPreWarn, 1;

TPWrite "SYNCHRONIZATION PRE WARNING. ";

RETURN;

ENDTRAP

PROC initSync()

CONNECT irSyncPreWarn WITH tpSyncPreWarn;

! 20470 SC 1 Synchronization Pre-warning

IError SYSTEM_ERR\ErrorId := 470,TYPE_ALL,irsyncPreWarn;

ENDPROC

ENDMODULE

Synchronization on closing edgeThe synchronization is executed 1 second after the sync switch is closed. The 1second delay is implemented to avoid synchronization pulses before the manipulatorhas stopped in its synchronization position.Nothing happens when the sync switch is opened again.

Cyclic Sync Check outputVirtual output signals can be connected to physical output signals forcommunication with a PLC. See also Virtual signals on page 67.



Continued

5.2 Synchronization guidelines for Software Sync Check

Selecting software synchronizationVerify that Software Synchronization was selected in the configuration.See Set sync position on page 47.

Uniquely defined positionThe robot position for the sync check must be chosen so that the position of therobot axes are unambiguously defined. One way to make sure the sync checkposition is well-defined for all axes is to use the instruction MoveAbsJ to move tothe sync position. See Technical referencemanual - RAPID Instructions, Functionsand Data types.Note that the sync position should be within the axis ranges configured for MonitorAxis Range to avoid that the robot stops on the way to the sync position.

Use easily verified sync positionSelect a sync position where it is easy to verify the position of the robot axes. It ishelpful to use a position where the TCP touches a spike or something where it iseasy to see if the robot is in the correct position or not.

Use service routine to perform synchronization

WARNING

If the robot position is not visually verified, to make sure all robot axes are incorrect position, the synchronization can jeopardize the safety.

Note

Software synchronization can only be performed by a user with grants that allowthis, see Create a safety user on page 37.

Action

Move the robot to its sync position(for example with MoveAbsJ).

1

If an axis is in wrong position, the revolution coun-ters are most likely incorrect.

Visually verify that the robot is inits sync position (all axes must bein correct position).

2



5 Synchronization5.2 Synchronization guidelines for Software Sync Check

Action

en0400001109

In the program view, tap Debugand select Call Routine.

3

Select the service routine Soft-wareSync and tap Go to.

4

Follow the instructions in the ser-vice routine.

5


5 Synchronization5.2 Synchronization guidelines for Software Sync Check

Continued

6 Running in production6.1 Reaction time

Output signal response timeWhen a robot axis moves outside its configured range, the reaction time until thesafe digital output signal goes low is maximum 4 ms.


6 Running in production6.1 Reaction time

6.2 Recovery after safety violation

Auto Stop or General StopWhen an axis is outside its defined range, Electronic Position Switches sets anoutput signal low. What is done with this signal depends on the installation. Onerecommended way of connecting the output signals is so that they affect the AutoStop signal or the General Stop signal. See Connect to Auto Stop on the panelboard on page 31 and Connect to General Stop on the panel board on page 31.

Recovery from Auto StopIf an axis is outside its defined range and causes an Auto Stop:

1 Switch the controller to manual mode.2 Jog the robot back within the defined ranges for all axes.

As soon as all axes are within their defined range, the Auto Stop is releasedand you can continue.

Recovery from General StopIf an axis is outside its defined range and causes a General Stop:

1 Switch the controller to manual mode.2 Safely close the safety circuit (e.g with a dead man’s handle) while jogging

the robot back within the defined ranges for all axes.As soon as all axes are within their defined range, the General Stop isreleased and you can continue.


6 Running in production6.2 Recovery after safety violation

6.3 Virtual signals

What is a virtual signalThe virtual signals can be viewed on the FlexPendant, but they are communicatedover the Ethernet connection and not a physical signal. They show the status ofsignals from the safety controller and cannot be set by the user, which is why theare represented as digital inputs (DI).The virtual signals can be used by a RAPID program to produce helpful hints tothe operator of why the robot has stopped.

WARNING

The virtual signals must not be used for safety implementation. Only the physicalsignals can be used for safety implementation.

List of signals

DescriptionSignal name

Representation of the input signal from the sync switch to the safetycontroller.

PSC1CSC

Representation of the MAR1 signal from the safety controller.PSC1MAR1





Request to do synchronization check. The value is 1 if the prewarningtime for Cyclic Sync Check has expired.

PSC1CSPREWARN

All other virtual signals starting with PSC (Positional Safety Controller) are forinternal use. Do not use them for customer applications.

Signals for MultiMove systemIn a MultiMove system there is one set of signals from each safety controller, i.e.from each drive module that is equipped with a safety controller. Signals from drivemodule 1 have names starting with PSC1, signals from drive module 2 have namesstarting with PSC2, etc.


6 Running in production6.3 Virtual signals

6.4 Status LED

Location of the status LEDA red/green status LED is placed on the front panel of the safety controller. Itindicates the status of the safety controller.

14

1

xx0900000242

Status LEDA

Status indications

DescriptionLED indication

Safety controller CPU is running and communication is ok.Solid green

Internal hardware failure. Replace the safety controller.Solid red

Communication failure or I/O power supply missing.Flashing green


6 Running in production6.4 Status LED

7 Example application7.1 Example with two work zones

AssignmentA robot cell consists of one robot and two positioners. The robot should be ableto work on a work piece held by one positioner while an operator change workpiece held by the other positioner.There are two light curtains protecting that no personnel enters the station wherethe robot is working.

Safetyinstru ctions

Light curtain 1 Light curtain 2

Station 1Station 2

en0700000215

Configure Monitor Axis Range signalsTo implement the safety solution, two Monitor Axis Range signals must beconfigured. The first signal should be high as long as the robot is not in station 1(when it is safe for personnel to enter station 1). The second signal should be highwhen the robot is not in station 2.The following picture illustrates how these two signals are configured for robotaxis 1 in the EPS Configuration Wizard.

en0700000212




The following picture shows the angles for robot axis 1 where the signals (MAR1and MAR2) are high (green) and where they are low (red).

Safetyinstru ctions

MAR1MAR2

Light curtain 1 Light curtain 2

Station 1Station 2

en0700000214

Connecting signals to Auto StopThis is a description of the principle for how to connect the signals. The light curtainssignals are high when they are untouched and low when the operator is in thestation. The safety condition that is to be implemented is that the operator and therobot must not be in the same station.Note that this illustration only shows single channels. In reality duplication will beused for the following:

• dual output signals from the safety controller (e.g. MAR 1A and MAR 1B)• dual output signals from the light curtains• dual Auto Stop signals (Auto Stop 1 and Auto Stop 2)• implement the logical gates with two channel safety relays, two channel

safety PLC, or similar equipment




Continued

en0700000213

For more details about the connections, see section Hardware installation onpage 25.

Note

The logical blocks in the picture are principal blocks. To make a safe installationthese blocks must be realized using safety components fulfilling relevant safetystandards for the installation.

Note

If other safety equipment is connected to Auto stop, make sure that the safetychain can be broken by any of the safety implementations.

Note

Use dual channels in the real implementation.



Continued


8 Safety aspects for Electronic Position Switches8.1 Overview

OverviewElectronic Position Switches, EPS, is an additional safety computer in the IRC5robot controller, with the purpose of providing safe output signals representing theposition of robot axes. The output signals are typically connected to cell safetycircuitry and/or a safety PLC which takes care of interlocking in the robot cell, forexample, in order to prevent robot and operator to enter a common areasimultaneously.In this chapter we describe how EPS comply with relevant safety standards andregulations.


8 Safety aspects for Electronic Position Switches8.1 Overview

8.2 Safety requirements

8.2.1 Standards conformance

StandardsEPS has been designed to fulfill applicable parts of the following standards.

• EN ISO 12100-1:2003 Safety of machinery - Basic concepts, general principlesfor design - Part 1: Basic terminology, methodology

• EN ISO 12100-2:2003 Safety of machinery - Basic concepts, general principlesfor design - Part 2: Technical principles

• EN 1050 Safety of Machinery, Principles of Risk Assessment• EN 60204-1 Safety of machinery - Electrical equipment of machines - Part

1: General requirements• EN ISO 10218-1:2006, Robots for industrial environments - Safety

requirements - Part 1: Robot• EN 61000-6-2 EMC, Generic immunity• EN 61000-6-4 EMC, Generic emission• EN 954-1:1999 Safety of machinery - Safety related parts of control systems

- Part 1: General principles for design• EN ISO 13849-1:2006 Safety of machinery - Electrical equipment of machines

- Part 1: General requirements (will replace EN 954-1 in Dec. 2009)• Applicable parts of ANSI/RIA R15.06-1999• IEC 61508, Functional safety of electrical/electronic/programmable electronic

safety related systems• IEC 62061, Safety of machinery - Functional safety of safety-related electrical,

electronic and programmable electronic control systems• Applicable parts of UL 1740, "Industrial robots and robotic equipment"• CAN / CSA Z434-03


8 Safety aspects for Electronic Position Switches8.2.1 Standards conformance

8.2.2 Specific safety requirements

Specific safety requirements for Electronic Position SwitchesElectronic Position Switches shall comply with EN ISO 10218-1 in general andspecifically comply with chapter 5.4, that is, the following requirements.When safety related control systems are required, the safety related parts shall bedesigned so that:

• A single fault in any of these parts shall not lead to the loss of the safetyfunction.

• Whenever reasonably practicable, the single fault shall be detected at orbefore the next demand upon the safety function.

• When the single fault occurs, the safety function is always performed and asafe state shall be maintained until the detected fault is corrected.

• All reasonably foreseeable faults shall be detected.This requirement is considered to be of category 3 as described in EN 954-1:1999(EU harmonization of ISO 13849-1:1999), which is the current and valid standardfor safety of machinery. Category 3 is normally fulfilled by redundant circuits, likedual channels, which is the case for EPS. EPS together with the robot controlleralso complies with performance level (PL) "d" according to EN ISO 13849-1:2006,and SIL 2 according to IEC 61508.


8 Safety aspects for Electronic Position Switches8.2.2 Specific safety requirements

8.3 Safe design of Electronic Position Switches

OverviewElectronic Position Switches, EPS, has two important supervision functions.The first one being to ensure that the axis computer and the drive system areworking correctly, making the robot follow the ordered value from the main computeras expected.The second being to supervise the robot position and setting outputs low to indicateif the robot is in a hazardous area.

Supervision of axis computer and drive systemEPS is a separate and from the IRC5 independent device mounted in the drivepart, close to the axis computer.The EPS board is connected to the communication link between the main computerand the axis computer, thus reading the absolute motor position values sent asreference to the axis computer. The EPS board is also connected to thecommunication link between the Serial Measurement Board (SMB) and the axiscomputer, and thereby reading the actual rotational motor position values. Sincethese values are within one revolution, the absolute position is calculated by addingvalues from internal revolution counters in both the axis computer and in EPS.By comparing these values, that is the ordered motor position and the actual motorposition, Electronic Position Switches can detect any difference (outside a permittedlag deviation) between the two positions, thereby ensuring that the drive systemis working properly according to the first supervision function as described above.It is important to ensure that the safety controller and the robot controller aresynchronized. The safe sync position is defined during configuration and storedin the safety controller. Synchronization can be done by activation of a switch orby software depending on the applicationTo detect such errors, the robot can be ordered to go regularly to a synchronizationswitch, which will generate a synchronization pulse to EPS confirming that therobot revolution counter is correct. In some applications it is more feasible to dothe synchronization check by software.In this position EPS will also calculate the robot joint positions and check againsta stored value to confirm that the synchronization is correct, covering the followingpoints.

• EPS is working correctly with the right revolution counter value.• The right manipulator is used.• The calibration value is correct.• The SMB is working correctly.



8 Safety aspects for Electronic Position Switches8.3 Safe design of Electronic Position Switches

Category 3 supervisionThis supervision complies with category 3, as described above, since two separatechannels that is, the axis computer with the drive system, motors, resolvers, andmeasurement system (channel 1) and the ordered value from the main computer(channel 2) shall always give the same result using the EPS evaluation circuits,which in itself is dual channel, see illustration below.

Additional safety designAdditional safety, over and above what is formally required, is brought to theconcept by the inherent dual channel character of the resolver, thanks to its dualsine and cosine output, where the square sum is supervised to be close to 1.Also the single channel synchronization check is complying with category 3, evenif only one synch signal channel is used. The two channel requirement is in thiscase fulfilled in two ways:

1 Check that the input signal is changing its value, that is has a flank, indicatingthat the switch is working.

2 The double check of both receiving a physical synch pulse and the checkthat the actual robot position corresponds to the stored value for the syncposition.




Continued

Illustration, dual channel concept

xx0800000198

Channel 1C1

Channel 2C2

Actual valuex1

Ordered valuex2

Axis computerAC

Drive systemDS

MotorM

ResolverR

Serial measurement boardSMB

Safety controller (EPS board)SC

Supervision of robot positionThe second supervision function (to supervise the robot position and setting outputslow to indicate if the robot is in a hazardous area) is fulfilled by letting EPS comparethe robot position with limit values configured by an authorized user (so calledSafety User). If any axis (or combination of axes) is outside its defined safe area,the supervision will activate an output. Active outputs are set to low, so that theyare valid also at power failure. There are five outputs which each can represent anarbitrary combination of all robot axes (as selected by the Safety User).To ensure that also this supervision complies with the category 3 requirement,EPS is inside working with a two channel microprocessor based system, whereone channel is handling the actual position and the other the ordered position. Theoutputs from EPS are also each consisting of two channels, thus preserving thecategory 3 requirement.



Continued

8.4 Certifications

OverviewEPS has been certified by external organizations as described below.

BGIA concept certificationBerufsgenossenschaftliche Institut für Arbeitsschutz in Germany made a conceptcertification with the following result.The concept of EPS complies with:

• Category 4 according to EN 954-1• SIL 3 according to EN 61508• Cat. 4 and PL e according to ISO 13849-1

Note

Electronic Position Switches as a part of the IRC5 controller is category 3 andPL d, even though the unit itself fulfills category 4 and PL e.

UL certificationEPS is approved by UL according to the following standards:

• UL 1740• UL 1998• ANSI / RIA R15.06• CAN / CSA Z434-03• ANSI / RIA 10218-1:2007 (which is the US harmonized ISO 10218-1:2006)

Note

Since ISO 10218-1:2006 thus is harmonized in EU as well as in North Americas,the UL certification clearly shows that EPS fulfills the EU Machinery Directive.In addition to this and since ISO 10218-1 refers to ISO 13849-1:1999 as anormative reference, it is also shown that EPS complies with the category 3requirements.


8 Safety aspects for Electronic Position Switches8.4 Certifications

8.5 Conclusion

ConclusionAs has been shown above and confirmed by third party certifications, ElectronicPosition Switches fulfills all relevant current safety standards globally.


8 Safety aspects for Electronic Position Switches8.5 Conclusion

IndexAactivating the safety configuration, 56additional axes, 14additional axis, 28, 34, 41Auto Stop, 31, 66axis range, 17–18

Bbus, 33

Ccalibration position, 51check cycle, 47cold start, 57configuration file, 54connections, 25, 28, 30continuous rotating axes, 17Control Error Supervision

description, 22–23current data, 26Cyclic Sync Check

configuring, 47description, 20guidelines, 61

Ddownload to controller, 48drive module, 39, 54dual input signal, 28dual output signals, 29

EEPS Configuration Wizard, 39

FFlexPendant, 60

GGeneral Stop, 31, 66ground potential, 32

II/O connector, 25, 30I/O signals, 28independent axes, 40inductive load, 29input signal, 26, 28invert function, 43i-start, 57

LLED, 68limitations

safety controller, 14

Mmechanical unit, 40, 54Monitor Axis Range

configuring, 43description, 17

monitoring, 16motor calibration file, 49motor calibration offset, 42MoveAbsJ, 61, 63MultiMove, 39, 54, 56

Nnon-zero calibration position, 51

Ooccupationally safe, 16operationally safe, 16Operational Safety Range

configuring, 23, 47description, 22–23

output signals, 26, 29

Ppanel board, 31PIN code, 49, 56PLC, 30, 32power supply, 32PSC1CSC, 67PSC1MAR1, 67PSC1PREWARN, 67

Rrange, 17–18reaction time, 65recovery, 66redundancy, 27, 29relay, 30robots, 14

Ssafe input, 16safe output, 16safety, 11safety bus, 33safety calibration file, 49safety configuration, 56safety controller, 13, 16, 25, 54safety relay, 30safety user, 37service routine, 63servo lag, 22–23, 47signals, 26, 28, 30, 67

antivalent, 16equivalent, 16

single input signal, 28SMB, 34soft servo, 23, 47software installation, 35Software Sync Check

configuring, 47description, 21guidelines, 63

SoftwareSync service routine, 63status LED, 68supported additional axes, 14supported robots, 14sync check, 47synchronization

description, 20–21guidelines for Cyclic Sync Check, 61guidelines for Software Sync Check, 63

sync position, 20, 47, 61, 63sync switch, 28, 30


Index

Ttest pulses, 29tolerance, 47tool, 61

Vvirtual signal, 67voltage data, 26

Wwarm start, 57


Index

Contact us

ABB ABDiscrete Automation and MotionRoboticsS-721 68 VÄSTERÅS, SwedenTelephone +46 (0) 21 344 400

ABB AS, RoboticsDiscrete Automation and MotionBox 265N-4349 BRYNE, NorwayTelephone: +47 51489000

ABB Engineering (Shanghai) Ltd.5 Lane 369, ChuangYe RoadKangQiao Town, PuDong DistrictSHANGHAI 201319, ChinaTelephone: +86 21 6105 6666

www.abb.com/robotics

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